Impact sensors and systems including impact sensors

ABSTRACT

An impact sensor system includes at least one impact sensor including at least a first conductive layer, at least a second conductive layer, and at least one insulating layer between the first conductive layer and the second conductive layer. The insulating layer maintains the first conductive layer and the second conductive layer in spaced, non-contacting relation. The first conducting layer and the insulating layer are deformable upon an impact to the first conducting layer such that separation between the first conducting layer and the second conducting layer decreases upon an impact of a predefined nature. The impact sensor system also includes circuitry in connection with the impact sensor to measure a change in at least one electrical property of the impact sensor resulting from the decrease in the separation between the first conducting layer and the second conducting layer. A body armor system to be worn by a person includes at least one section of body armor and at least one impact sensor associated with at least a section of the body armor.

RELATED APPLICATIONS

This application claims priority on U.S. Provisional Patent Application No. 60/919,370 filed Mar. 23, 2007, the entire disclosure of which is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to impact sensors and systems including such impact sensors and, particularly, to impact sensors and systems for use by personnel (such a law enforcement personnel, military personnel and the like) under conditions of potentially life-threatening impacts.

Ballistic resistant armor is used in many applications including, for example, protection of vehicles and persons from impacts from ballistic and other threats. Body armor to be worn on a person for protection from, for example, ballistic, knife, stab, spike and other threats, has been available for several decades. In general, body armor protects vital parts of the human torso against penetration and severe blunt trauma as, for example, generated by ballistic projectiles. Monolithic and multi-component ceramic plates have been used in a number of hard body armors (that is, body armors including hard projectile resistant components or plates). See, for example, U.S. Pat. No. 6,253,655 and Canadian Patent No. 2,404,739, the disclosures of which are incorporated herein by reference. Improved hard body armor systems are disclosed in U.S. Pat. No. 7,284,470, the disclosure of which is incorporated herein by reference. Relatively soft or pliant body armor, providing increased comfort for the user, often includes ballistic panels or packages formed, for example, from DuPont's KEVLAR® ballistic grade fibers/fabrics. Improved soft body armor systems are disclosed in U.S. patent application Ser. No. 11/405,221, filed Apr. 17, 2006, and assigned to the assignee of the present invention, the disclosure of which is incorporated herein by reference.

Although both hard and soft body armor are quite effective in preventing penetration by ballistic threats, it would be desirable to provide an alarm to, for example, notify a command post or base in the case of a ballistic or other severe impact. In that regard, injuries to individuals equipped with body armor can and do occur, requiring that assistance be provided to such individual. Moreover, even absent an injury, an impact indicates that the individual is likely to be in need of immediate assistance.

Outside of the field of body armor, there have been a number of attempts to provide systems that sense when a wearer has been impacted by an object. For example, wearable piezoelectric force sensors have been used to detect the amount of force delivered to a competitor's body in martial arts competitions. See, for example, Chi, E. H., Introducing Wearable Force Sensors in Martial Arts, Pervasive Computing, IEEE CS (July-September 2005). In such systems, a body protector worn by a competitor is provided with such force sensors. Upon sensing an impact, a wireless transmitter sends a signal of the sensed impact to a judge's computer that scores and displays points.

Wearable force sensing systems have also been developed for use in the field of wearable computing. For example, ELEKTEX fabrics available form Eleksen Inc. of Waltham, Massachusetts have been used to form wearable, wireless fabric keyboards and controllers. The fabric operates by detecting changes in conductivity across an intricate web of conducting fibers through which current flow is maintained. A processor operating specialized software monitors the fabric, determining where deformations occur when the fabric is pressed.

Many currently available force sensor systems have power consumption requirements that make the sensor systems unsuitable for use in connection with mobile personnel, such as personnel equipped with body armor. Other types of force sensor systems are not suitably robust to provide reliable sensitivity in the case of, for example, a ballistic impact.

Thus, although wearable force and impact sensors have been developed in a number of fields, it remains desirable to develop a sensor system suitable for use by personnel under conditions of potentially life-threatening impacts, and particularly, by personnel equipped with body armor systems.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides an impact sensor system including at least one impact sensor including at least a first conductive layer, at least a second conductive layer, and at least one insulating layer between the first conductive layer and the second conductive layer. The insulating layer maintains the first conductive layer and the second conductive layer in spaced, non-contacting relation. The first conducting layer and the insulating layer are deformable upon an impact (for example, an impact of a predefined nature such as of a predetermined force etc.) to the first conducting layer such that the separation between the first conducting layer and the second conducting layer decreases upon the impact. The impact sensor system also includes circuitry in connection with the impact sensor to measure a change in at least one electrical property of the impact sensor resulting from the decrease in the separation between the first conducting layer and the second conducting layer.

In one embodiment, at least a portion of the first conductive layer contacts the second conductive layer upon the impact. In such an embodiment, the impact sensor can operate in the manner of a switch and current flows through at least a portion of the circuitry only upon contact between the first conducting layer and the second conducting layer. In another embodiment, the circuitry measures a change in capacitance of the impact sensor resulting from the decrease in the separation between the first conducting layer and the second conducting layer.

The impact sensor system can further include at least a second insulating layer and at least a third conductive layer. The second insulating layer can be positioned between the third conductive layer and the second conductive layer. The second insulating layer maintains the third conductive layer and the second conductive layer in spaced, non-contacting relation. The second conducting layer and the second insulating layer are deformable upon an impact (for example, of a predefined nature) to the second conducting layer such that the separation between the second conducting layer and the third conducting layer decreases upon the impact. The circuitry can further be adapted to measure a change in at least one electrical property of the impact sensor resulting from the decrease in the separation between the second conducting layer and the third conducting layer.

In another embodiment, at least a portion of the second conductive layer contacts the third conductive layer upon the impact. In such an embodiment, the impact sensor can operate in the manner of a switch and current flows through at least a portion of the circuitry only upon contact between the second conducting layer and the third conducting layer. In another embodiment, the circuitry measures a change in capacitance of the impact sensor resulting from the decrease in the separation between the second conducting layer and the third conducting layer.

The impact sensor system can include a plurality of impact sensors positioned, for example, in a grid.

Insulating layers of the impact sensors of the present invention can, for example, have a thickness of less than 1 mm. Conducting layers separated by such insulating layers (for example, the first conducting layer and the second conducting layer) can, for example, have a thickness in the range of approximately 20 μm to approximately 1000 μm.

In another aspect, the present invention provides a switch including at least a first conductive layer, at least a second conductive layer and at least one insulating layer between the first conductive layer and the second conductive layer. The insulating layer maintains the first conductive layer and the second conductive layer in spaced, non-contacting relation. The first conducting layer and the insulating layer are deformable upon an impact or application of a force (for example, of a predefined nature) to the first conducting layer such that the first conducting layer contacts the second conducting layer upon the impact or the application of the force.

In another aspect, the present invention provides a system for detecting an impact to a person wearing the system, including an impact sensor as described above, at least one control system to monitor the impact sensor system and determine if an impact has occurred, and at least one communication system in operative connection with the control system. The communication system can, for example, be adapted to transmit a signal upon determination of an impact by the control system.

The control system can, for example, include a microprocessor. The communication system can, for example, include a cellular phone or radio module. The system can further include a recording system in operative connection with the control system. The recording system can, for example, be adapted to record environmental sounds upon determination of an impact by the control system.

The system can further include an actuator adapted to communicate an alarm via the communication system upon manual activation by the person.

The impact sensor can, for example, be adapted to sense penetration of the sensor by a projectile.

In several embodiments, the communication system includes a communication unit in connection with the control system. The communication unit includes a wireless transmitter to communicate with at least one other component of the communication system positioned remote from the communication unit. The communication system can, for example, further include a cellular phone or radio module positioned remote from the communication unit and including a wireless receiver to communicate with the communication unit.

In still a further aspect, the present invention provides a body armor system to be worn by a person, including at least one section of body armor and at least one impact sensor. The impact sensor can, for example, be an impact sensor as described above. The body armor system can further include at least one control system to monitor the impact sensor to determine if an impact has occurred. The body armor system can also further include a communication system in operative connection with the control system as described above.

In several embodiments of the present invention, a communication port can be provided in communicative connection with the control system which is adapted to be connected to a computer to enable entry of control data. Further an indicator such as an audio source (for example, a speaker) can be provided in operative connection with the control system to provide an alarm (for example, an audible alarm) upon determination of an impact by the control system or upon manual activation.

The present invention, along with the attributes and attendant advantages thereof, will best be appreciated and understood in view of the following detailed description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates an embodiment of a system of the present invention in which an impact sensor of the system is illustrated in cross section.

FIG. 1B illustrates an embodiment of body armor in the form of a body armor vest (for example, a ballistic resistant vest, a stab resistant vest and/or a spike resistant vest) including a system of the present invention wherein a communication system of the system is remote from several other components of the impact sensor of the system.

FIG. 2 illustrates an embodiment of a impact sensor such as described in FIG. 1 after a non-piercing impact.

FIG. 3A illustrates the impact sensor of FIG. 1 after penetration or piercing by an object such as a bullet.

FIG. 3B illustrates a screen capture of a graphical representation of a measured voltage (v) as a function of time in a circuit including the impact sensor of the present invention operating as a switch.

FIG. 4 illustrates an embodiment of a multilayer impact sensor of the present invention.

FIG. 5 illustrates an embodiment of a multi-sectional impact sensor of the present invention for localizing the point of an impact.

FIG. 6 illustrates a perspective view of a portion or section of an impact sensor of the present invention.

FIG. 7 illustrates a screen capture of a setup page associated with control software for use in connection with the impact sensors of the present invention.

FIG. 8A illustrates one embodiment of a communications system using a radio.

FIG. 8B illustrates another embodiment of a communications system using a radio.

DETAILED DESCRIPTION OF THE INVENTION

In several embodiments of the present invention, an impact sensor in, for example, the form of an open circuit, switch or capacitor provides efficient power consumption characteristics, suitable sensitivity and suitable robustness for use in connection with personnel (for example, law enforcement personnel, tactical squad personnel, SWAT personnel, military personnel etc.) under conditions of potentially life-threatening impacts. In that regard one embodiment of a system 10 of the present invention as illustrated in FIG. 1A includes an impact sensor 20 including a first conductive layer 30 and a second conductive layer 40. In the illustrated embodiment, first conductive layer 30 is the outer layer with respect to the wearer's body. First conductive layer 30 and second conductive layer 40 are maintained in spaced, non-contacting relation to each other (represented, for example, by separation “d” in FIG. 1A) until an impact (for example, of a predetermined level of force) occurs. Upon impact of an object with first conductive layer 30, at least a portion of first conductive layer 30 deforms toward second conductive layer 40. Such deformation of sensor 20 results in a measurable change in at least one electrical property (for example, resistance, capacitance etc.) of sensor 20. A voltage difference can, for example, be maintained across first conductive layer 30 and second conductive layer 40 via, for example, a power source such as a battery 50. Once first conductive layer 30 deforms sufficiently to contact second conductive layer 40, a closed circuit is formed or the resistance is reduced as compared to the open circuit state and a measurable current results. In general, no current flows through sensor 20 before an impact of sufficient force occurs to bring first conductive layer 30 into contact with second conductive layer 40. Thus, the power requirement of sensor 20 are relatively low (indeed, zero before an impact) and the life of battery 50 can cover an extended period of time. Further, a measurable change in capacitance results as an impact begins to deform sensor 20, decreasing the thickness of the insulating layer 60 in the area of the impact.

In several embodiments of the present invention, first conductive layer 30 and second conductive layer 40 are maintained in spaced, non-contacting relation to each other via a deformable insulating layer 60 (that is, a layer of an insulating, nonconductive material) positioned between first conductive layer 30 and second conductive layer 40. Insulating layer 60 prevents contact of first conductive layer 30 with second conductive layer 40 under normal (nonimpact) conditions, thereby maintaining sensor 20 in the state of an open switch. Upon impact of a suitable force, insulating layer 60 deforms to, for example, allow contact of deforming first conductive layer 30 with second conductive layer 40.

FIG. 2 illustrates the effect of an impact of an object upon first conductive layer 30 of sensor 20 and the resultant deformation of first contact layer 30 (and insulating layer 60) to locally decrease the separation between first contact layer 30 and second conductive layer 40 (to, for example, cause first contact layer 30 to come into contact with second contact layer 40). FIG. 3A illustrates the effect of an impact of a piercing or penetrating object such a bullet, blade, spike or knife upon sensor 20. Without limitation to any particular mechanism of operation, it is believed that the portions of first conductive layer 30 around the periphery of the resulting hole in sensor 20 are brought into contact with second conductive layer 40, thereby closing the circuit in which sensor 20 is in electrical connection to function, for example, in a manner similar to a switch. A graphical representation of a resultant measured voltage in that circuit is, for example, set forth in FIG. 3B. At time 0.0, the penetrating impact occurs, closing the circuit, and causing current to flow through the circuit. A change in current or voltage of more than a predefined threshold can be determined to be an impact event.

Various materials can be used in conductive layers 30 and 40. For example, such materials can include flexible metallic sheets. Conductive woven fabrics (for example, metallic woven fabrics or metal-plated woven fabrics), conductive carbon materials, polymer/metal composite materials and conductive polymeric materials can also be used. Various insulating materials are also suitable for use in insulating layer 60. For example, various insulating woven fabrics, insulating gels, insulating polymeric materials (including, but not limited to, open-celled foams, polymeric sheets or films, resilient polymeric beads, polymeric fabrics and other polymeric materials) and/or other insulating materials can be used. As clear to one skilled in the art, the amount of force required to cause senor 20 to indicate an impact can be readily predetermined by choice of an insulating material of appropriate physical characteristics. In that regard, the thickness and deformability of insulating layer 60 determine the amount of impact force required to provide a sensed impact event such as illustrated in FIGS. 2 and 3A. In general, insulating layer 60 is preferably maintained relatively thin or minimized in thickness so that the separation between first conductive layer 30 and second conductive layer 40 is maintained relatively small, providing for improved impact sensitivity. For example, insulating layer 60 can have a thickness of less that approximately 1 mm, less than approximately 0.5 mm and even less than approximately 0.25 mm. Conductive layers 30 and 40 are preferably of sufficient thickness and malleability such that a positive result is obtained upon, for example, penetration of sensor 20 as illustrated in FIG. 3A. For example, conductive layers 30 and/or 40 can have a thickness in the range of approximately 20 μm to approximately 1000 μm, or in the range of approximately 20 μm to approximately 500 μm.

In several studies of the present invention, sensor 20 included conductive layers 30 and 40 formed from sheets of aluminum separated by a plastic. In several, other studies of the present invention a commercially available, double-sided copper printed circuit board (PCB) material was used as sensor 20. The flexible PCB material was purchased from Cross and Bradley Ltd of the United Kingdom under part no. PCL3-17/25-FR, wherein the copper outer layers were 17 μm thick and the intermediated insulating layer was 25 μm thick. In still other studies, conductive fabric (fabric woven from metal—(for example, Ni, Cu, Ag, etc.) plated polyethylene terephthalate (PET) fibers) available from Anjinelectron of Korea was used as the conductive outer layers and a thin layer of an insulating polymeric film was used as the insulating layer. The results set forth in FIG. 3B are for an impact sensor including such conductive fabric for conducting layers 30 and 40 with an insulating polymeric film therebetween for insulating layer 60. The conducting layers were adhered to the insulating layer. Double sided adhesive tape or other adhesive materials as known in the art can be used to attach the various layers of the impact sensors of the present invention. Stitching is preferably avoided as stitching can result in forming conductive contact between the conducting layers.

FIG. 4 illustrates an embodiment of a multilayer sensor 20′ of the present invention which includes a first conductive layer 30′, a second conductive layer 40 a′ and a third conductive layer 40 b′. A first insulating layer 60 a′ separates first conductive layer 30′ and second conductive layer 40 a′. A second insulating layer 60 b′ separates second conductive layer 40 a′ and third conductive layer 40 b′. Providing sensors having multiple layers or layered switches can, for example, provide redundancy for improved reliability. Moreover, differences in insulating layer thicknesses and composition can provide for different sensed states as a result of different impact forces, thereby enabling identification or differentiation of the nature/force of different impacts. Upon application of the force of an impact to the outer layers of such a multilayer sensor, deformation of the outer layers translates the force/impact to inner layers of the sensor causing deformation thereof as described above. Each set or pair of conducting layers separated by an insulating layer can, for example, be in electrical connection with a circuit as described above to measure any change in electrical properties associated with an impact to the sensor.

As illustrated, for example, in FIG. 5, a sensor 120 of the present invention can be divided into a plurality of sections 122 that are electrically separated. Providing such a grid system can enable a determination of the position on a wearers body at which an impact has occurred. FIG. 6 illustrates one of sections 122 overlain upon a section of a hard or soft ballistic armor system 200 as described, for example, in U.S. Pat. No. 6,253,655 and/or in U.S. patent application Ser. No. 11/405,221. As discussed above in connection with, for example, sensor 20, each of sections 122 of sensor 120 includes a first conductive layer 130 separated from a second conductive layer 140 by an intermediate insulating layer 160.

Impact sensors for use in connection with body armor systems of the present invention can operate in a manner other than or take forms other than the open circuits or switches described above. In that regard, in several embodiments a change in capacitance can be measured. Such impact sensors can have a structure similar to the impact sensor 40 of FIG. 1A. However, instead of monitoring for a short circuit or reduction in resistance from an essentially open circuit to a resistive value of, for example, a few kilohms (for example, resulting from contact between the conductive layers) as described above, one can monitor for a sudden change in capacitance as would occur when an impact begins to deform the impact sensor and make the insulated thickness locally thinner. A change in separation “d” between the conductive layers, increases the capacitance momentarily. The change in capacitance can, for example, be detected using an oscillator that uses the capacitance value as part of a frequency generating circuit. In such a system, one would detect a sudden change in frequency.

Alternatively, an impact sensor of the present invention can include material that generates a voltage upon an impact. For example, a body armor system of the present invention can include an impact sensor which can include a piezoelectric material (for example, a polyvinylidene fluoride or PVDF piezo film) adjacent body armor. The piezoelectric film can be a single film or sheet (as opposed to a laminate) that simply generates a voltage spike when the film, sheet or other form of impact sensor is deformed or stressed. It is not required to maintain a voltage across the film or sheet. The voltage generated by deformation or stress of the impact sensor can be used to, for example, trigger electronics to “wake up” and send an alarm signal (as described further below) if the voltage is, for example, above a certain threshold associated with an impact of a predetermined nature.

Still further, an impact sensor can measure shock waves resulting from an impact. Such an impact sensor can, for example, include a gel layer (for example a foam material filled or impregnated with a gel). When an impact occurs, a shock wave travels through the material (similar to the ripples produced in a pool of water after dropping a pebble therein). The impact sensor includes a sensor that monitors for such a shock wave. The sensor can, for example, include a piezoelectric element that is deformed by the arrival of the shock wave. Alternatively, the sensor can include a microphone. A threshold can, for example, be set to create an alarm signal upon detection of an impact of a predetermined nature.

Returning to FIG. 1A, system 10 of the present invention can also include a control system 70. Control system 70 can, for example include a processor 72 (for example, a microprocessor). Microprocessor 72 can, for example, include software to monitor the state of the circuit of which sensor 20 (or other impact sensor as described above) is a part, determining if a measured voltage/current or other measured signal is above a threshold or within a range associated with an impact event. System 10 can further include a sound recording system 74 (including, for example, a microphone 76 and recording memory (such as a removable microdisk or other digital storage media as known in the art). Upon determination of an impact event, recording system 74 can be activated such that the sounds/voices associated with the local environment are measured/recorded by microphone 76 for a period of time after the impact event.

System 10 can further include a communication system 80 in communicative connection therewith. Communication system 80 is preferably operable to transmit a signal of an impact event back to a command post or base (for example, to a police station or central control in the case of a police officer equipped with sensor 20). In one embodiment, existing cellular phone infrastructure, represented by antennae 100, is used to transmit messages/information. Communication system 80 can, for example, include a dual-tone, multi-frequency (DTMF) decoder system 82 to effect tone dialing, which is used by most public switched telephone networks (PSTN) for number dialing and is also used to provide for transfer of small amounts of data. A cell phone module 84 in communicative connection with an antenna 86 can also be provided. Wireless broadband internet services can also be used as such become more commonly available. Wireless Enhanced 911 (E911) services can also be used in the present invention.

In another embodiment, an existing standard radio carried by first responders and other emergency personnel is used to transmit messages 200 and information from impact sensor 20. Communications module 210 is connected to radio 200 via the radio's remote speaker/microphone jack. Communications utilizes the radio's power. Upon incident microphone feed to the radio and broadcasts a user defined distress call and user location to a predefined radio channel while continuously recording live feed for a predetermined amount of time. User programming could be made possible via the use of a USB connection. Alternatively, the electronics for the communications module may be contained as a separate unit 200 that would then be interconnected to the police radio 200 by the remote speaker/microphone jack. This unit would further have the ability to be connected to a remote speaker/microphone 230 of the user's choice.

System 10 can, for example, include a communication port 81 (for example, a USB port or a wireless communication module) for connection of system 10 to a personal computer operating, for example, a general purpose operating system such as MICROSOFT WINDOWS® to program certain aspects of system 10 as described below. Communication port 81 can, for example, be part of communication system 80.

In addition to transmissions to a command post or base, communication system 80 can also communicate with other communication systems 80 in the vicinity thereof or range thereof in the case of an impact or penetration (such as a gunshot). Such communication can, for example, be effected via, a communication unit 80 a (such as a radio frequency transmitter/transceiver as described further below) and can provide additional assurance that an alarm message will be received and acted upon quickly. Communication unit 80 a can, for example, send a signal that can be received by all like systems 10 in the range thereof.

In another embodiment, an existing standard radio carried by first responders and other emergency personnel is used to transmit messages 200 and information from impact sensor 20. Communications module 210 is connected to radio 200 via the radio's remote speaker/microphone jack. Communications module 200 utilizes the radio's power. Upon incident notification from sensor 20, the module 210 intermittently intercepts the microphone feed to the radio and broadcasts a user defined distress call and user location to a predefined radio channel while continuously recording live feed for a predetermined amount of time. User programming could be made possible via the use of a USB connection. Alternatively, the electronics for the communications module may be contained as a separate unit 220 that would then be interconnected to the police radio 200 by the remote speaker/microphone jack. This unit would further have the ability to be connected to a remote speaker/microphone 230 of the user's choice.

In several embodiments, communication system 80, or a portion thereof, as described above was remote from, but in wireless communication with, other electronics of system 10. As illustrated, for example, in FIG. 1B, that portion of the electronic circuitry to monitor the state of the circuit of which sensor 20 (a perimeter which is shown in dashed lines within body armor 200 in FIG. 1B) is a part can be in wired connection with sensor 20, which is associated with body armor 200 in the form of a vest. As use herein, the term “body armor” refers to resistant armor worn on the person of a user. Such body armor can be ballistic resistant, stab resistant and/or spike resistant as, for example, defined in the National Institute of Justice Ballistic Resistance of Person Body Armor NIJ Standard-0101.06 and in the National Institute of Justice Stab Resistance of Personal Body Armor NIJ Standard-0115.00 of the U.S. Department of Justice. In the case of an impact or puncture event (or in the case that other data is to be transmitted) a wireless signal can be sent, for example, via an RF transmitter/transceiver of communication unit 80 a to “remote” communication system 80. Remote communication system 80 can, for example, be kept within a short distance from sensor 20. In the illustrated embodiment, communication system 80 is positioned within a pouch attached to the user's trouser leg. However, communication system 80 can, for example, be positioned anywhere associated with the user that is convenient to the user. Communication system 80 can for example be a standard radio unit carried by first responders and other emergency personnel. Alternatively, it can be a cell phone module.

Wireless communication unit 80 a can, for example, operate similar to a vehicle key fob that communicates via radio frequency (RF) transmission to a vehicle (for example, a car). Such devices require very little power. Indeed, batteries used in such devices rarely if ever require changing. Each system 10 can have its own serial code or other unique identifier.

Communication system 80 can, for example, “learn” to which system 10 it is associated. In one embodiment, system 10 can be supplied with a label having a unique serial number thereon. When one or more systems 10 arrive at a destination (for example, a police station, a military post etc.) system 10 can be connected (for example, via USB cable via a wireless connection) to a computer and all the relevant data installed from the computer, including, for example, the system serial numbers, the telephone numbers for the text and voice messages, and pre-recorded voice messages (see FIG. 7 and the discussion thereof below). The serial number for each system can, for example, be saved into a memory of cell phone module 84. Alternatively, information can be manually entered and/or transmitted via, for example, bar codes, RFID etc.

In another embodiment, a switch 82 a was placed in communicative connection with communication unit 80 a. When system 10 is shipped from the manufacturer, communication unit 80 a in system 10 can, for example, be in a non-transmitting mode. This mode or state can, for example, assist in maintaining battery charge. Moreover, regulations may not permit air shipment if communication unit 80 a of system 10 is in a transmitting mode. Upon arrival at its final destination, communication unit 80 a can be activated by actuating switch 82 a. In several embodiments, when communication system 80 is placed in communication (for example, via a USB connection) to a computer, and switch 82 a is actuated (whether or not it has been previously actuated), communication unit 80 a transmits a short burst of RF energy, providing the serial number and/or other information associated with system 10. This procedure makes bar coding or other labeling of the transmitted information by the manufacturer unnecessary and avoids the need for a corresponding bar code reader (or other sensor/reader system) at the customers site.

Positioning communication system 80 remote from the remainder of system 10 can, for example, provide a number of advantages. For example, communication system 80 can be relatively large in comparison to other components and it can be difficult to position communication system 80 on or within body armor 200 without causing inconvenience to the user. This is particularly the case if communications system 80 is a radio. Moreover, remote positioning of communication system 80 can simplify wiring and reliability of components associated with body armor 200. Furthermore, given the low power requirements of other components of system 10, battery 50 can, for example, be sealed and not be replaceable. Communication system 80 can include its own power source 88 (for example, a battery). Battery 88 can be a replaceable and/or rechargeable battery. Battery 88 can remain operable over an extended period (for example, in excess of one year). In several embodiments, communication system 80 senses when battery 88 is low in charge (using sensing systems as known in the art), and communicates a signal to, for example, a command or base station that battery 88 should be replaced.

System 10 can also include one or more subsystems to monitor the state of system 10. In one embodiment as illustrated in FIG. 1A, a resistor 34 can be placed in electrical connection across two conductive layers 30 and 40, preferably away from the actual potential contact points for sensor 20. Resistor 34 facilitates an electronic check for short or open circuits in system 10. In that regard, periodically, power from battery 50 can be applied across conductive layers 30 and 40 to check that a current (preferably a very small current, as a result of using a resistor having a relatively high resistance) is flowing to indicate that the sensor circuit is not broken. Alternatively, a check can be made to determine if capacitance is in the right order of magnitude. A check of capacitance has the advantage of not imposing a continuing drain on battery 50. Such system checks also will provide an indication if there is a short circuit within system 10. While communication system 80 is in communication with system 10, a short circuit should also trigger an alarm as described above. Any problems detected in a periodic check of system 10 can be communicated to communication system 80 to advise the user and thereby provide a warning that system 10 associated with body armor/vest 200 may not be functioning properly.

In cases in which commercial cellular phone communications networks are used, text or voice charges can be avoided for system test transmissions by having communication system 80 call a predetermined or fixed telephone number and then hanging up before that number is answered. However, the receiving telephone can log or otherwise note the incoming number using systems and methods known in the communication arts.

In another embodiment, cell phone module 84 of communication system 80 can, for example, be programmed to call the predetermined telephone number and hang up as described above. Manual activation can also be made possible. The receiving phone system can, upon receipt of the call, call back the telephone number associated with communication system 80. Upon making a connection (for example, after a few rings) the calling phone can hang up. This receipt of the call signal by communication system 80 completes the test of system 10 and of communication system 80. Upon successful completion of such a test, an indication such as a green LED on cell phone module 84 of communication system 80 or other indication can be activated, thereby indicating that the test was completed successfully. If a problem had been detected, (for example, one or more broken contacts, battery 50 determined to be low, etc.) then cell phone module 84 of communication system 80 does not make the call to the predetermined telephone number (or calls and does not hang up), thereby providing an indication of a problem. Further, the successful test indicator (for example, a green LED on cell phone module 84) will not be activated and the user will know there is a problem.

In another embodiment, cell phone module 84 can be programmed to call a specific telephone number periodically (for example, every 24 hours). As described above, it can be programmed to (if there is no fault or problem) hang up after, for example, two rings. In this embodiment, the command or home base can be equipped with a phone system 300 (see FIG. 1B) adapted to receive the call from cell phone module 84, note its number and record the time of call. In the event that a call is not received within a suitable time limit, phone system 300 will highlight a possible malfunction and the command or home base will be able to make contact with the user to resolve the problem. If there has been a fault or problem to report, cell phone module 84 can, for example, be programmed to not hang up when it makes the call to phone system 300. Cell phone module 84 can, for example, wait several or more rings (for example, six rings) until phone system 300 answers and then report the detail of the fault. The details of the report can be logged by phone system 300 and highlighted for further action at the command or home base.

Alternatively, text and/or voice messaging available from commercial cellular phone services can be used in such self testing methodologies.

It is possible that sensor 20 can be inadvertently or accidentally impacted, penetrated or punctured. In several embodiments, an alarm procedure was initiated upon such an event as described above. Further, an indication or local alarm that is detectible by the user was also initiated. For example, an alarm such as an audible alarm via an audio source 78 (for example, a speaker) could be initiated. Further, communication unit 80 can be provided with a vibrating mechanism 89 (as known, in the cellular phone arts) that can, for example, vibrate every few seconds (for, example, every 15 seconds) to indicate to the user that an alarm call was in progress. In this manner, the user gains comfort knowing that an emergency call had been transmitted. Further, if the incident arose from a false alarm (for example, an inadvertent puncture of sensor 20), the user could call in to the command post or base to cancel the associated alarm, thereby avoiding a substantial backup and/or rescue operation.

In several studies of the present invention, the control system and communication system included an MC56 GSM Modem (US triband version) available from Siemens, a PIC micontroller (PIC 16F6520), an ISD4001 sound recording chip, an MT88L70 DTMF tone decoder (Mitel Semiconductor), an SSM2167 Audio VOGAD (Voice Operated Gain Adjusting Device) (Analog Devices), a CP2102 USB interface (silicon laboratories), power regulators, an electret microphone, a dual band 800/1900 MHz antenna, and an SIM (Subscriber Identity Module) card and holder.

Any number of system operation and communication schemes can be used in the present invention. For example, in one embodiment, microphone 76 begins recording upon sensing of an impact event as described above. Upon establishing a communication link with a base, a text SOS message can be sent via, for example, short message service (SMS) available via cellular phone service to one or multiple recipients. A prerecorded voice message can also be sent to the base. Spoken identification of the system can facilitate operator understanding of an alarm without the need for or intervention of computers, databases etc. Likewise, a predetermined amount of the environmental recording initiated upon sensing the impact event can also be transmitted. After transmission of any recording or immediately upon forming a connection, microphone 76 can be used to transmit live sound/voice. Sound recording of the incident can, however, continue. Two-way communications can also be established via cell phone module 84. Cell phone module 84 can also be used to send information via the Internet or a wireless Internet connection can be made directly via, for example, processor 72 and attendant hardware as known in the art.

Cellular phone module 84 and radio 200 can also be used as a locator (using triangulation methods known in the art). Other location system such as GPS etc. can additionally or alternatively be used. An alarm can also be sounded via a audio source 78 to assist in locating the individual wearing sensor 20.

Various cell phone protocols including GSM, CDMA, GPRS, UMTS, PCS and others can be used in the present invention. GSM, for example, typically provides relatively fast connect times. It is used widely in Europe and is gaining in popularity in the United States.

FIG. 7 illustrates an example of a graphical user interface for use with a computer in communicative connection with cellular phone module 84 for programming certain aspects of the operation of system 10. A user can, for example, use the user interface to enter the name of the wearer of, for example, a ballistic vest including the system of the present invention. A primary voice call telephone number and a backup voice telephone number to call, for example, upon an impact event can also be entered. Likewise, one or more (three, in the illustrated embodiment) telephone numbers for short message service text/data messages can be entered. As described above, a serial number for system 10 to associate communication system 80 with the remainder of system 10 can also be entered (or otherwise transmitted). Controls are also provided for initiating recording of an alarm message, an assist message and a test message. Upon entry of the desired data, an update button can be actuated to transmit the data to system 10 (via, for example, communication/data port 81). Such data can also be saved and recalled from a data disk or hard drive associated with the computer.

While the present invention has generally been described in connection with a communications system that includes a cellular phone, the communications in the present invention can additionally or alternatively be effected via a radio system and as is commonly carried by police and other emergency personnel. As illustrated in FIG. 1A, a module 90 can be provided to communicatively connect system 10 to a radio system such as a police radio system or to a secure radio system as used in military applications. A low power transmitter/transceiver such as radio frequency communication unit 80 a of FIG. 1B can also be used as an intermediate communications link between system 10 and such a communication system.

In addition to establishing a communication link upon sensing of an impact event as described above, a silent alarm/communication link can also be established manually via a manual actuator 92 to send a silent alarm should the individual equipped with system 10 be in need of assistance.

The foregoing description and accompanying drawings set forth the preferred embodiments of the invention at the present time. Various modifications, additions and alternative designs will, of course, become apparent to those skilled in the art in light of the foregoing teachings without departing from the scope of the invention. The scope of the invention is indicated by the following claims rather than by the foregoing description. All changes and variations that fall within the meaning and range of equivalency of the claims are to be embraced within their scope. 

1-4. (canceled)
 5. The apparatus of claim 14, wherein the at least one impact sensor comprises a plurality of electrically-separated impact sensors arranged in a grid, wherein each electrically-separated impact sensor of the plurality of electrically-separated impact sensors corresponds to a region of anatomy of a wearer that wears the body armor system. 6-8. (canceled)
 9. The apparatus of claim 14 wherein the control system comprises a microprocessor.
 10. The apparatus of claim 14 further comprising a sound recording system in operative connection with the control system.
 11. The apparatus of claim 14 further comprising a manually-operable alarm actuator communicatively-coupled to the communication system.
 12. The apparatus of claim 14, wherein each of the first conductive layer and the second conductive layers include a flexible material, wherein the flexible material includes a metallic sheet, conductive woven fibers, a conductive carbon material, a polymer/metal composite material, or a conductive polymeric material.
 13. The apparatus of claim 20 wherein the communication system comprises: a transmitter unit communicatively-coupled to the control system, wherein the transmitter unit includes a wireless transmitter that is communicatively-coupled with one or more of a local receiver and a remote receiver.
 14. An apparatus, comprising: a body armor system including: at least one panel section of ballistic resistant armor and at least one impact sensor positioned outside of and adjacent to at least a panel section of ballistic resistant armor; wherein the at least one impact sensor includes a multi-layer structure having a first conductive layer, a second conductive layer, and an insulating layer disposed between the first conductive layer and the second conductive layer, wherein an overall thickness of the multi-layer structure includes an entire thickness of each of: the first conductive layer, the second conductive layer and the insulating layer, wherein the multi-layer structure is arrangeable in one of: a non-impact orientation, and an impact orientation, wherein the non-impact orientation includes the insulating layer including a substantially constant thickness that maintains the first conductive layer and the second conductive layer in a spaced-apart, non-contacting relationship without upsetting the overall thickness of the multi-layer structure, wherein the impact orientation includes a portion of the insulating layer not maintaining the spaced-apart, non-contacting relationship of the first conductive layer and the second conductive layer such that a portion of the first conductive layer directly contacts a portion of the second conductive layer, wherein the impact orientation of the multi-layer structure includes one of: a non-pierced orientation and a pierced orientation, wherein the pierced orientation includes a passage that extends through the overall thickness of the multi-layer structure, wherein the entire thickness of the insulating layer is not constant when the multi-layer structure is arranged in the non-pierced orientation, wherein the body armor system further comprising circuitry in connection with the impact sensor and control system. 15-16. (canceled)
 17. The apparatus of claim 14, wherein the portion of the first conductive layer directly contacting the portion of the second conductive layer, the first conductive layer is in electrical communication with the second conductive layer.
 18. The body armor system of claim 14 wherein the insulating layer includes a woven fabric, an insulating gel, an open-celled foam, a polymeric sheet or resilient polymeric beads.
 19. The apparatus claim 14 further comprising a third conductive layer, and a second insulating layer disposed between the third conductive layer and the second conductive layer.
 20. The apparatus of claim 14 further comprising a communication system communicatively-coupled to the control system.
 21. (canceled)
 22. The apparatus of claim 20, wherein the communication system includes a communication port that communicatively-couples the control system to a computer.
 23. The apparatus of claim 14 wherein the entire thickness of the first conductive layer is between approximately about 20 to 1000 μm, wherein the first conductive layer is formed from a malleable conductive material, wherein the entire thickness of the insulating layer is less than approximately about 1 mm.
 24. A method, comprising the steps of: providing at least one impact sensor of a body armor unit including: a first flexibly-malleable conductive layer, a second flexibly-malleable conductive layer, and a flexibly-malleable insulating layer disposed between the first flexibly-malleable conductive layer and the second flexibly-malleable conductive layer; maintaining a non-impact orientation of the at least one impact sensor by utilizing the flexibly-malleable insulating layer to retain the first flexibly-malleable conductive layer and the second flexibly-malleable conductive layer in a spaced-apart, non-contacting relationship; malleably-deforming the at least one impact sensor by flexibly-moving the first flexible conducting layer through an entire thickness of each of the second flexibly-malleable conductive layer and the flexibly-malleable insulating layer such that the flexibly-malleable insulating layer fails to maintain the first flexibly-malleable conductive layer in the spaced-apart, non-contacting relationship with respect to the second flexibly-malleable conductive layer such that a portion of the first flexibly-malleable conductive layer directly contacts a portion of the second flexibly-malleable conductive layer; communicative-coupling circuitry with the at least one impact sensor; and utilizing the circuitry for detecting and communicating a change in at least one electrical property resulting from the portion of the first flexibly-malleable conductive layer directly contacting the portion of the second flexibly-malleable conductive layer.
 25. The method of claim 24 wherein the at least one impact sensor includes a plurality of electrically-separated impact sensors arranged in a grid, the method further comprising the step of: associating each electrically-separated impact sensor of the plurality of impact sensors with a region of anatomy of a wearer that wears the body armor unit.
 26. The method of claim 24 further comprising the step of: communicatively-coupling a recording system to the at least one impact sensor; and recording environmental sounds upon the portion of the first flexibly-malleable conductive layer directly contacting the portion of the second flexibly-malleable conductive layer.
 27. The method of claim 24 further comprising the step of: communicatively-coupling a manually-operable alarm actuator to the at least one impact sensor; and transmitting an alarm upon manual activation of the manually-operable alarm actuator.
 28. The method of claim 24 further comprising the step of: communicatively-coupling a communication system to the at least one impact sensor; and transmitting a signal to a receiver upon the portion of the first flexibly-malleable conductive layer directly contacting the portion of the second flexibly-malleable conductive layer.
 29. (canceled) 